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  1. 14th January 2017, 02:35 PM #1
    spart
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    Default Carousel Progress

    With a large amount of spare time of late I decided to have a go at building a miniature working carousel, (I have carved quite a few full size carousel horses in the past) . I started with a MDF cover sheet drawing different size circles on it to arrive at a diameter of 900mm which allowed room for 20 horses in 3 rows, the horses range from 170-230mm which gives room for a fair bit of detailed carving. The horses are carved from 150x75X250 clears pine blocks, I split them into 150x25x250 & traced the patterns onto them.
    I then cut them out with the band saw, before gluing I align the 3 pieces and drill 2 holes for 100mm nails to stop slippage when glued and cramped, ( don't forget to remove nails once clamped, I should have rotated the timber leg pieces so the grain ran along the legs as the legs are prone to breaking). I made a mock up, as pictured, to work out the lift amount etc, with rubber tyre model car wheels to mount the lift ramps.
    I decided to make plywood pulleys to reduce my 1/4 HP 1750 RPM motor down to 5-6 RPM this required a 3 belt system jumping from 40-250mm each pulley set, only trouble was small ply pulleys split and the motor would not start without some assistance.
    Search Mr Google.
    Take 2 : Changed drive to 240volt barbecue rotisserie suitable for 20kilo piece of meat, another failure! Search Mr Google again.
    Take 3 : Resurrect pulley system, replace small ply pulleys with hardwood & look into fitting capacitor starter to motor failing that source bigger motor with starter.
    Rounding boards on top edge carved 1, made latex mould and cast with plaster.
    Will post more when finished.7 reduced (2).jpg4 reduced.jpg1 reduced.jpg5 reduced.jpg2 reduced).jpg8 reduced 2.jpg6 reduced.jpg3 reduced.jpg
    Last edited by spart; 15th January 2017 at 09:43 AM. Reason: images to large
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  2. 14th January 2017 02:35 PM # ADS
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  3. 14th January 2017, 03:19 PM #2
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    Repliconics
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    Looks fantastic!
    Some of your pictures don't seem to be showing up at the moment.
    I'd love to see them.
    But what I can see looks wonderful!.

    Cheers
    Trev.
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  4. 14th January 2017, 04:11 PM #3
    cava
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    Wow.

    Do you have any plans for this?
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  5. 14th January 2017, 05:58 PM #4
    Lappa
    Lappa is offline Woodworking mechanic
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    That is absolutely stunning! Fantastic work.

    On a side note, what was the problem with the barbecue rotisserie?
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  6. 14th January 2017, 06:16 PM #5
    spart
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    Nothing like enough grunt, balanced rotisserie has no drag, carousel has wheels rising over ramps and table rolls on wheels all create resistance.
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  7. 14th January 2017, 06:17 PM #6
    spart
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    No sorry made it up as I went.
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  8. 14th January 2017, 06:18 PM #7
    spart
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    Sorry about that should have them repaired tomorrow.
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  9. 15th January 2017, 08:12 AM #8
    Keith_1
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    Top work

    Looks great

    Regards

    Keith
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  10. 16th January 2017, 07:57 PM #9
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    crowie
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    Must agree, fantastic carousel sir......
    I wish the photos were bigger to see all the details.... thank you,
    cheers, crowie
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  11. 17th January 2017, 07:30 AM #10
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    Christos
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    That's incredible, you have spare time on your hands?

    Sorry just being a little cheeky. Really appreciate that you are sharing this build.
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  12. 27th January 2017, 11:55 AM #11
    spart
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    I had to make a modification so took the opportunity to take images of the 3 belt speed reduction pulleys, rise & fall ramps and the ice block stick in the top of the poles to stop the horses rotating (the pegs are to hold the ramp wheels clear to avoid damage when lifting the main body off & on the base).
    IMG reduced_9220.jpgIMG_reduced 9221.jpgIMG_reduced 9222.jpgIMG_reduced 9225.jpg
    I will post more images as I progress with ticket booth stairs etc.
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  13. 27th January 2017, 12:16 PM #12
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    Repliconics
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    Very interesting to see the way you made the gearing.

    Cheers
    Trev.
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  14. 27th January 2017, 01:20 PM #13
    old1955
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    WOW...just doesn't cover it.
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  15. 30th January 2017, 09:49 PM #14
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    Handyjack
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    Now I understand how the horses rise and fall without the normal cranks. A picture tells a thousand words.
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  16. 26th February 2017, 03:09 PM #15
    spart
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    Well that was a failure! The carousel wouldn't turn, couldn't stop the belts slipping on the last pulley set (not enough belt grip on the 40mm pulley) because of the weight and the friction of the wheels on the lifting ramps plus I had a problem with the 1/4 HP motor starting without a bit of assistance. I have done a complete rebuild of the drive. I have now gone to 4 pulley sets, 2x40-260mm, 1x100-260mm, 1x75-260mm giving much better belt grip plus I upgraded the motor to 1/2HP with capacitor start & run, It now starts and runs without assistance.
    IMG_9246.jpgIMG_9251.jpg
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